Air Distribution Housing
HOUSING-AIR DISTRIBUTIONNOTE: LHD model with A/C shown in the following illustrations. RHD and heater-only models are similar.
DISASSEMBLY
NOTE: The air distribution housing must be removed from the HVAC housing and disassembled for service of the blend-air and mode-air doors.
1. Remove the HVAC housing assembly and place it on a workbench .
2. Remove the air distribution housing (2) from the HVAC housing (1).
3. Remove the temperature control cable from the driver side of the air distribution housing.
4. Remove the screw and washer (1) that secures the blend door lever (2) to the driver side of the air distribution housing (4) and remove the lever.
NOTE: Remove the blend door pivot lever by carefully pulling it straight out from the end of the blend door pivot shaft.
5. Remove the blend door pivot lever (3) from the end of the blend door pivot shaft.
6. Remove the mode door cable from the passenger side of the air distribution housing.
7. Remove the screw (2) that secures the mode door cable lever (1) to the passenger side of the air distribution housing (3) and remove the lever.
NOTE: Remove the two mode door pivot levers by carefully pulling them straight out from the end of the mode door pivot shafts.
8. Remove the two mode door pivot levers (1 and 2) from the end of the mode door pivot shafts on the passenger side of the air distribution housing (3).
NOTE: If the foam seal on the air distribution housing outlets is deformed or damaged, the seal must be replaced.
9. Carefully cut the foam seal (1) along the parting line (2) of the two halves of the air distribution housing (3). If the seal is deformed or damaged, it must be replaced.
10. Remove the seven screws and one clip (4) that secure the two halves of the air distribution housing together.
11. Carefully separate the left half of the air distribution housing from the right half of the housing.
12. Remove the air deflector (2) from inside of the air distribution housing (3).
NOTE: If a seal on an air door is deformed or damaged, the air door must be replaced.
13. Remove the air door(s) (1, 4 and 5) from the air distribution housing, as required.
ASSEMBLY
NOTE: If a seal on an air door is deformed or damaged, the air door must be replaced.
1. Install the air door(s) (1, 4 and 5) into the air distribution housing (3), as required. Align the air door(s) with the pivot shaft hole(s) in the housing.
2. Install the air deflector (2) into the air distribution housing.
3. Align the air door pivot shafts the pivot shaft holes in the air distribution housing (3) and carefully install the left half of the air distribution housing to the right half of the housing.
4. Install the seven screws and one clip (4) that secure the two halves of the air distribution housing together. Tighten the screws to 2.2 N.m (20 in. lbs.).
NOTE: If the foam seal on the air distribution housing outlets is deformed or damaged, the seal must be replaced.
5. Inspect the foam seal (1), especially at the parting line (2). If the foam seal is deformed or damaged, it must be replaced.
NOTE: Install the two mode door pivot levers by carefully pushing them straight into the end of the mode door pivot shafts.
6. Install the two mode door pivot levers (1 and 3) into the end of the mode door pivot shafts (2) on the passenger side of the air distribution housing (4). Make sure the levers are fully engaged to the shafts.
NOTE: Align the pins on the mode door pivot levers with the grooves in the cable lever prior to installation of the cable lever.
7. Position the mode door cable lever (1) onto the passenger side of the air distribution housing (3). Make sure the pins on the mode door pivot levers are positioned in the grooves of the cable lever.
8. Install the screw and washer (2) that secure the mode door cable lever to the air distribution housing. Tighten the screw to 2.2 N.m (20 in. lbs.).
9. Install the mode door cable onto the passenger side of the air distribution housing.
NOTE: Install the blend door pivot lever by carefully pushing it straight into the end of the blend door pivot shaft.
10. Install the blend door pivot lever (3) into the end of the blend door pivot shaft on the driver side of the air distribution housing (4). Make sure the lever is fully engaged to the shaft.
NOTE: Align the pin on the blend door lever with the grooves in the blend door pivot lever prior to installation of the blend door lever.
11. Position the blend door lever (2) onto the driver side of the air distribution housing. Make sure the pin on the blend door lever is positioned in the grooves of the pivot lever.
12. Install the screw (1) that secures the blend door lever to the air distribution housing. Tighten the screw to 2.2 N.m (20 in. lbs.).
13. Install the temperature control cable onto the driver side of the air distribution housing.
14. Install the air distribution housing (2) onto the HVAC housing (1).
15. Install the HVAC housing assembly.